Method of making a hardcore panel and panel made thereby

ABSTRACT

A method of making a hardcore panel comprising the steps of providing a stack of planar boards of grained lumber fastened together and arranged in the stack in step-wise fashion, cutting the stepped stack on the first cut line through the side faces thereof at a predetermined acute angle, such as 12-30*, between the cut line and the bottom face of the stack and making subsequent coplanar cuts in this stack at predetermined distances from each other providing a plurality of cut segments whose top, front, bottom and rear faces are rectangular and whose side faces are rhomboidal. These cut segments are then sub divided into a plurality of coplanar pieces which are fastened together with alternate pieces being inverted 180* about a longitudinal axis through the center of the piece so that each of the piece adjacent end faces for every other one of these pieces of battenlike members forms the predetermined acute angle with the longitudinal axis of the piece whereas the end faces of the alternate pieces each form a predetermined obtuse angle with the longitudinal axis of the piece which is supplement art of the predetermined acute angle. The direction of the grain of each of the obtuse angular related pieces is supplementary to the direction of the grain of each of the acute angular related pieces. Such a hardcore panel may be produced by this method and, if desired, a veneer layer may be fastened to either the top or bottom or both faces of the hardcore panel, contrasting colored woods may be utilized to provide a decorative panel or veins of lesser thickness than the other board portions comprising the batten-like member may be utilized for providing such a decorative panel. Furthermore, grooves may be provided in either the top, bottom, or both surfaces of the panel to further provide a decorative hardcore panel.

United States Patent [191 Kiefer METHOD OF MAKING A HARDCORE PANEL AND PANEL MADE THEREBY [76] Inventor: John Kiefer, 713 E. 6th St., New

York, NY. 10009 [22] Filed: Apr. 30, 1974 [2]] Appl. No.: 465,493

Related U.S. Application Data [63] Continuation-in-part of Ser. No. 351,671. April 16. 1973, Continuation of Ser. No 118,216, Feb. 24,

1971, abandoned.

Primary Examiner-William E. Schulz Attorney, Agent, or Firm Hubbell, Cohen and Stiefel [57] ABSTRACT A method of making a hardcore panel comprising the steps of providing a stack of planar boards of grained lumber fastened together and arranged in the stack in step-wise fashion cutting the stepped stack on the first [451 July 15, 1975 cut line through the side faces thereof at a predetermined acute angle. such as 12-30", between the cut line and the bottom face of the stack and making subsequent coplanar cuts in this stack at predetermined distances from each other providing a plurality of cut segments whose top, front, bottom and rear faces are rectangular and whose side faces are rhomboidal. These cut segments are then sub divided into a plurality of coplanar pieces which are fastened together with alternate pieces being inverted 180 about a longitudinal axis through the center of the piece so that each of the piece adjacent end faces for every other one of these pieces of batten-like members forms the predetermined acute angle with the longitudinal axis of the piece whereas the end faces of the alternate pieces each form a predetermined obtuse angle with the longitudinal axis of the piece which is supplement-art of the predetermined acute angle. The direction of the grain of each of the obtuse angular related pieces is supplementary to the direction of the grain of each of the acute angular related pieces Such a hardcore panel may be produced by this method and, if desired, a veneer layer may be fastened to either the top or bottom or both faces of the hardcore panel, contrasting colored woods may be utilized to provide a decorative panel or veins of lesser thickness than the other board portions comprising the batten-like member may be utilized for providing such a decorative panel. Furthermore, grooves may be provided in either the top, bottom, or both surfaces of the panel to further provide a decorative hardcore panel.

29 Claims, 26 Drawing Figures FIG. 2 606 60a 1 FIG. 3A 626 F/G.3D

FIG. 4

METHOD OF MAKING A HARDCORE PANEL AND PANEL MADE THEREBY CROSS REFERENCE TO RELATED APPLICATIONS This application is a continuation-in-part of copending application, Ser. No. 351,671, filed Apr. 16, 1973, which is a continuation of application, Ser. No. 118,216, filed Feb. 24, 1971, now abandoned, the contents of both said applications being hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention related to hardcore panels and methods of making such panels.

2. Description of the Prior Art Various types of wood decorative or structural members are well known such as disclosed in U.S. Pat. No. 2,578,781 in which diagonal glued plywood board is provided in which bias-grained sheets of veneer are cut at a right angle to their edge into any desired length and two or more pieces in this manner are then assembled face to face so that their scissor strip joints and the grain of the wood in each alternate ply crosses at right angles. This plywood does not utilize multi ply rhomboidal strips. The construction disclosed in this reference is purportedly more economical than conventional rectangular plywood but is not utilizable to obtain a hardcore panel without veneering, which veneering is the basis of the process in this reference. Other such prior art construction requiring the use of a veneer is disclosed in U.S. Pat. No. 1,734,826, the core being cross banded with the veneer in this reference. Other prior art compositions utilizing laminated wood to construct a multiply laminate, all of which are different from the invention described herein are disclosed in U.S. Pat. Nos. 2,172,093; 2,389,944; 1,214,382; 3,389,041; 677,800; 800,993; 1,994,204 and 308,184.

SUMMARY OF THE INVENTION The present invention relates to a hardcore panel and a method of making this panel. The hardcore panel comprises a plurality of adjacent batten-like members fastened together in a substantially planar configuration with each of the batten-like members having a top face, an opposed bottom face, a pair of opposed end faces and a pair of opposed side faces, each of the faces being substantially normal to the adjacent face of the batten-like member. Each of these members comprises a fastened plurality of stacked adjacent angular board segments of grained lumber, each of the segments having a top face, an opposed bottom face, a pair of opposed end faces and a pair of opposed side faces with the board segments being stacked along the longitudinal axis of the batten-like member of one end face to the opposed end face. The adjacent angular board segment end faces are fastened together and are substantially parallel to each other with the adjacent angular board segment top, bottom and side faces, respectively. Each of the segment adjacent ends faces for every other one of the fastened batten-like members forms a predetermined acute angle, such as between 12 and 30 with the longitudinal axis, each of the adjacent end faces comprising the batten-like members adjacent to every other member forming a predetermined obtuse angle with the longitudinal axis which is supplementary to the predetermined acute angle. The grain of each of the segments comprising a given batten-like member preferably all run in the same direction between the top surface and the bottom surface with the direction of the grain on each of the obtuse angular related segments being supplementary to the direction of the grain of each of the acute angular related segments. In making such a hardcore panel, a stack of parallel substantially uniform width planar boards of grained lumber are fastened together and arranged in the stack in step-wise fashion and the stack is cut along coplanar cut lines through the side faces thereof at the predetermined acute angle formed between the cut lines and the bottom face of the stack to provide cut portions from the stack which have rectangular top, front, bottom and rear faces and rhomboidal side faces. These cutportions are further sub divided into substantially symmetrical segments which comprise the batten-like members which are alternately inverted and fastened together in the manner described above. If desired, a veneer may be fastened to the top, bottom or both of these surfaces of the hardcore panel, contrasting colors may be used for the various woods comprising each of the batten-like members to provide a decorative panel, veins of wood of a different thickness than the other wood members comprised in a batten-like member may be utilized for such a decorative panel, and grooves may be provided in the top, bottom or both such surfaces for such a decorative panel.

BRIEF DESCRIPTION OF THE DRAWINGS FIGS. 1,2,.30, 3b, 3c, 3d, 4,5,6 and 7 are illustrative of the preferred steps in the preferred method of the present invention;

FIG. 7 is illustrative ofa preferred embodiment of the hardcore panel produced in accordance with this method;

FIG. 8 is a side elevation of an alternative embodiment of the preferred method of the present invention illustrated in FIGS. 1 through 7; FIG. 9 is a side elevation ofa typical batten-like member produced in accordance with the alternative method of FIG. 8;

FIG. 10 is a perspective view of an alternative embodiment of the hardcore panel produced in accordance with the alternative method of FIGS. 8 and 9;

FIG. 11 is a perspective view of an alternative embodiment of the hardcore panel of FIG. 7;

FIG. 12 is an exploded fragmentary perspective view of the embodiment illustrated in FIG. 11;

FIG. 13 is a fragmentary plan view of an alternative embodiment of the hardcore panel illustrated in FIG.

FIG. 14 is a fragmentary side elevation view of the embodiment illustrated in FIG. 13;

FIG. 15 is a front elevation view of the embodiment illustrated in FIG. 13;

FIG. 16 is a fragmentary plan view of an alternative embodiment of the embodiment illustrated in FIG. I0;

FIG. 17 is a fragmentary side elevation in the embodiment illustrated in FIG. 16;

FIG. 18 is a front elevation of the embodiment illustrated in FIG. 16;

FIG. 19 is a fragmentary plan view of still another alternative embodiment in the arrangement illustrated in FIG. 7;

FIG. is a fragmentary side elevation of the embodiment illustrated in FIG. I9;

FIG. 21 is a front elevation of the embodiment illustrated in FIG. 19;

FIG. 22 is a fragmentary side view similar to FIG. 19 of an alternative embodiment of the present invention; and

FIG. 2.3 is a side elevation of the embodiment illustrated in FIG. 22.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawings in detail and intiially to FIGS. 30, 3b, 3c", 3d, 4,5,6 and 7, a preferred embodiment of a hard core panel, generally referred to by the reference numeral 3030, in accordance with the present invention is shown (FIG. 7 As shown and pre ferred in FIG. 7, the hardcore panel 30 preferably comprises a pluralith of adjacent batten-like members, four such members 32, 34, 36 and 38 being shown by way of example in FIG. 7, fastened together, such as preferably with a waterproof resin such as caseine glue, or any other conventional binding adhesive, in a substantially planar configuration, as illustrated in FIG. 7. Each of these batten-like members 32 through 38, preferably has a top face, an opposed bottom face, a pair of opposed side faces, and a pair of opposed end faces, these faces being designated 32a, 32b, 32c, 32d, 32e, and 32f, respectively, for member 32; 34a through 34], respectively for member 34; 36a through 36]", respectively for member 36', and 38a through 38]", respectively for member 38. As shown and preferred in FIG. 7, each of the faces of the batten-like members 32 through 38 is substantially normal to the adjacent faces. The fastening together of the batten-like members 32 through 38 previously described is preferably accomplished by gluing together adjacent side faces of the batten-like members, side face 320 being fastened to side faces 34d, side face 346 being fastened to side face 36d and side face 36c being fastened to side face 36d and side face 360 being fastened to side face 38d in the arrangement illustrated in FIG. 7. As shown and preferred in FIGS. 30, 3b, 3c, 3d, 4,5,6 and 7, each of the batten-like members 32 through 38 preferably comprises a fastened plurality of stacked adjacent angular board segments of grained lumberm five such segments 40, 42, 44, 46 and 48 being shown by way of example in FIGS. 3b, 3c, 3d, 4,5,6 and 7. These adjacent angular segments are preferably fastened together in the same fashion as adjacent batten-like members are fastened together by gluing with a waterproof resin, such as the caseine glue previously mentioned. As shown and preferred, each of the segments 40 through 48 inclusive comprising each of the batten-like members 32 through 38, has a top face, an opposed bottom face, a pair of opposed end faces and a pair of opposed side faces, these faces being designated 40a, 40b, 40c, 40d, 40e and 40f, respectively for segment 40; 42a through 42f, respectively, for segment 42; 44a through 44f, respectively, for segment 44; 46a through 46f, respectively, for segment 46; and 48a through 48f, respectively for segment 48. As shown and preferred in FIGS. 6 and 7, these board segments 40 through 48, inclusive, are preferably stacked along the longitudinal axis 50 of the batten-like member, such as batten-like member 32, by way of example, from one end 32f of the batten-like member 32 to the opposed end face 32 of the batten-like member 32. As shown and preferred in FIG. 7, segment end faces 40e, 42]", 42e, 44f, 44e, 46f, and 46e are parallel to each other, with the adjacent end faces 40e-42f, 42e-44f, 44e-46f, 46e-48 f being fastened together. End faces 40f and 48e are preferably normal to the top and bottom surfaces 320 and 32b by way of example of the respective batten-like member 32 and, as will be described in greater detail hereinafter, and are accomplished by cutting the parallel initially provided end faces 52 and 54 of the batten-like member produced in accordance with the preferred method of the present invention to be described in greater detail hereinafter. As is shown and preferred, the top, bottom and side faces of the fastened angular board segments 40 through 48 and the respective batten-like members 32 through 38, are fastened toghether to provide the planar top and bottom surfaces for the hardcore panel 30 as well as providing the top, bottom and side faces for the respective battenlike members, with the end faces 32e and 32f being provided by cutting end faces 40f and 482 off to form a normal or perpendicular end face between the top and bottom faces 32a and 32b, by way of example, of the respective batten-like member 32.

As shown and preferred in FIG. 4 and FIG. 12, which are exploded views, each of the batten-like members 32 to 38, respectively, is preferably identical in structure and configuration with the exception that adjacent batten-like members are rotated l about the respective longitudinal axis 50 so that for batten-like members 32 and 36, by way of exmaple, the respective end faces 40c, 42f, 42e, 44f, 44e, 46f, 46e, 48f form a predetermined acute angle d),, (1) 413, and 1),, respectively (FIGS. 4 and 6) with the longitudinal axis 50 of the respective batten-like member 32 or 36. Similarly, as shown in FIG. 4, preferably the alternate adjacent batten-like members 34 and 38, which are preferably identical, and the respective adjacent end faces 40e, 42f, 42e-44f, 44e-46f, and 46e-48f form a predetermined obtuse angle 3,, B B and B,, respectively (FIG. 4), with the longitudinal axis 50, with the obtuse angle 13,, through I? being equal and being supplementary to the predetermined acute angle d),, with d), through 6,, being equal. Preferably, :1), forms a predetermined acute angle between l2 and 30 with the longitudinal axis 50 and most preferably, forms an angle of l8 with the longitudinal axis 50. Accordingly, 8,, which is preferably supplementary thereto, forms an obtuse angle in the range of l50 to l68 and most preferably forms an angle of I62 with the longitudinal axis 50.

Preferably, each of the grained lumber segments 40 through 48, inclusive, has the grain thereof running in the same direction substantially parallel to the end surfaces 40e for segment 40, 42a for segment 42, 44e for segment 44, 46s for segment 46 and 48f for segment 48. Accordingly, as shown and preferred in FIG. 4, when segments 32 and 34 are fastened togehter in the hardcore panel 30, the respective grains thereof are cross-grained with the grain of member 32 running substantially at the acute angle of 0 and the grain of member 34 running substantially at the obtuse angle of 3,. Similarly, the grain of member 34 is preferably crossgrained with the grain of member 38 comprising the hardcore panel 30. If desired, however], all grains in a given batten-like member 32 through 38, need not run in the same direction from top surface to bottom surface although this is the presently most preferred embodiment. As also shown and preferred in FIGS. 4,5,6 and 7, the segments 40 through 48, inclusive, comprising the batten-like members 32 through 38, inclusive may preferably be of contrasting color for providing a decorative panel for hardcore panel 30. By way of example, segments 42 and 46 are shown as being contrasting in color with segments 40, 44 and 48 as well as with each other. In addition, as illustrated in FIGS. 9 and 10, if desired, one or more batten-like members 32 through 38 may preferably comprise, in addition to segments 40 through 48, which are all preferably all of the same thickness, additional segments 54, 56, 58 and 60, by way of example, which are of lesser thickness than the corresponding thickness of the segments 40, 42, 44, 46 and 48 and are respectively, sandwiched therebetween with segment 54 being sandwiched between segments 40 and 42, segment 56 being sandwiched between segments 42 and 44, segment 58 being sandwiched between segments 46 and 48. These boards of thinner thickness 54 through 60, preferably provide veins in the assembled hardcore panel a as illustrated in FIG. 10, by way of example, such as for providing a decorative panel as the hardcore panel 30a, which, by way of example, is illustratively shown as comprising five batten-like members 32, 34, 36, 38 and 62, with batten-like member 62 preferably being substantially identical to batten-like member 36. As shown and preferred in FIGS. 11 and 12, if desired, the hardcore panel 30 may be provided with one or more veneer layers, two such layers 70 and 72 being shown by way of example in FIGS. 11 and 12, which have a predetermined thickness and are fastened, such as by means of gluing as discussed previously, to the top face, and bot tom face respectively of the hardcore panel 30 to cover or sandwich the hardcore panel 30 in between the respective veneer layers 70 and 72. Such a configuration may be readily utilized in construction, such as, by way of example, for a door, or for a wall if desired, in which instance, if it is an interior wall in which only one side is viewed, then only one veneer layer, such as veneer layer 70 need be provided. The hardcore panel 30 provided in accordance with the above construction provides greater structural integrity than that normally provided by a composition such as press board, such as when the hardcore panel 30 is utilized for construction such as doors. In addition, as illustrated in FIGS. 13 through 22, various decorative panels may readily be provided utilizing hardcore panel 30 as the basis thereof. For example, as shown in FIGS. 13, 14 and 15, concave grooves 80, 82 and 84 may be provided in the top surface, by way of example, of the hardcore panel 30, illustratively shown as comprising eight batten-like members in FIG. 13, by way of example. By providing the grooves 80, 82 and 84 in the top surface, a swirling flowing pattern, of the type illustrated by way of example in FIG. 13 is provided in the top surface within the grooves 80, 82 and 84 to provide a decorative panel. Similarly, as shown in FIGS. 16, 17 and 18, another preferred arrangement for providing a decorative panel such as from hardcore panel 30a may be provided in which the top surface contains both concave grooves 90, 92, 94 and 96, by way of example, and convex portions 98, 100, 102, 104, 106, and 108, with portions 98, I02, 104 and 108 being illustratively shown as being one quadrant ofa cylindrical portion and portions 100 and 106 illustratively being shown as being half ofa cylindrical portion with, in addition, a planar central portion 110. This decorative panel illustrated in FIGS. 16 to 18, by way of example, is shown as comprising eleven batten-like members with a veneer layer 112 and 114 being provided for central portion on both the top and the bottom, respectively. As was previously described with reference to FIGS. 13 through 15, the concave grooves 90 to 96, inclusive, provide a swirling decorative effect within these grooves and, similarly, the convex portions 98 through 108, inclusive, also provide swirling effects within these portions to provide the decorative panel. Another typical preferred decorative panel is illustrated in FIGS. 19 through 23, wherein both the top and bottom surfaces of the hardcore panel 30 are provided with concave grooves therein, grooves 120, 122 and 124 illustratively shown as being in the top surface in FIG. 21 and concave grooves 126 and 128 being illustratively shown as being in the bottom surface in FIG. 21. In addition, the top surface contains convex portions 130 and 132, preferably, and the bottom surface preferably contains convex portions 134, 136 and 138, with portions and 134, and 126, 122 and 136, 132 and 122, and 124 and 138 preferably being illustratively shown as being substantially parallel for the respective batten-like member of the hardcore panel.

METHOD Referring now to FIGS. 1,2,3a, 3b, 3c, 3d, 4,5,6 and 7, the preferred method of the present invention for providing the hardcore panel 30 illustrated in FIG. 7 shall be described. Referring now to FIG. 1, a plurality of grained lumber boards 480, 460, 440, 420, and 400, five such boards being shown by way of example in FIG. 1, and which are all preferably of the same width, such as board seasoned to about 7 percent and heart cut, are preferably stacked in step-wise fashion as illustrated in FIG. 1. The boards may be of any desired width although preferably a width of three to four inches, designated by the letter W in FIG. 1, is pro vided, each board preferably having a thickness t, such as, by way of example, one half of an inch. Preferably, as illustrated in FIG. I, the five boards 400, 420, 440, 460 and 480 are identical thickness although this is not necessary in accordance with the present invention. Each of these boards is preferably planar and is rectangular in configuration, such as square boards. The width W of the boards preferably should not exceed 8 inches. These boards, which may be of contrasting color as previously described, such as boards 460 and 420 being contrasting in color to boards 400, 440 and 480, with respect to each other. These boards are fastened or bonded together, such as with a waterproof resin, such as caseine glue or any other bonding adhesive such as themoplastic or urea adhesives in conven' tional fashion, such as with a horizontal-action bonding press or with high-frequency heating. The number of boards 400 through 480, respectively, bonded together in the step-like stack is dependent on the length of the desired hardcore panel 30 previously described. Preferably, these bonded boards are planned true so that the bonded joint between adjacent boards is tight from layer to layer. Furthermore, the grain of each of the boards 400 to 400 inclusive, preferably runs in the same direction, such as from front face 482 of board 480 to rear face 484 of board 480 in the direction of arrow 486 illustrated in FIG. 1, the grain of boards 400, 420. 440 and 460 preferably being substantially parallel therewith. If desired, however, different grain directions may be utilized for the various boards comprising the stack. In fastening or bonding the various boards together in the stack illustrated in FIG. 1, the stack may be placed in a conventional horizontal action bonding press and subjected to a predetermined pressure, such as kilograms per square centimeter for the required pressing time of between I and 2 hours depending on the kind of adhesive. If desired, the stack may be taken out of the press before this time and kept under pressure thereafter with conventional clamping means. After a predetermined period of time, such as with gang or band saws followed by drying out of the moisture introduced by the adhesive. As shown and preferred in FIG. I, each of the boards in the stack has a front face 482, 462, 442, 422, 402, respectively, for boards 484, 460, 420 and 400; a rear face 484, 464, 444, 424, and 404, respectively for boards 480, 460, 440, 420 and 400; a top face 485, 465, 445, 425, 405, respectively for boards 480, 460, 440, 420 and 400 an opposed bottom face 487, 467, 447, 427 and 407 for boards 480, 460, 440, 420 and 400, respectively, and and a pair of side faces 488 and 489 for board 480, 468 and 469 for board 460, 448 and 449 for board 440, 428 and 429 for board 420, and 408 and 409 for board 400. The stack, generally referred to by the reference numeral 800, is preferably initially completely cut along a first cut line, 500 by way of example, at a predetermined acute angle such as preferably between 12 and 30 and most preferably l8, between the cut line 500 and the bottom face 407 of the stack 800. As used hereinafter throughout the specification and claims, the term cut line" is not meant to refer to a predetermined line marked on the surface but rather is meant to include a direction of cutting for the saw utilized, such as a conventional gang or band saw. With respect to the first cut along cut line 500, the pieces of lumber illustrated by cross hatching in FIG. 2 are preferably discarded as waste so as to provide a smooth continuous planar sloped surface for the front surface of the stack 800 which slope has an acute angle dn. Thereafter, the stack 800 is preferablu cut along a plurality of spaced apart cut lines 502, 504, 506, 508 and 510, illustrated in FIG. 2, by way of example, at predetermined acute angles (1) 41 d b and (1),, which all preferably form the same angle between the respective out line and the bottom face 407 on the track, to provide a plurality of parallel sloping surfaces, these cuts preferably being completely through from one side face to the other side face of the stack to provide a plurality of substantially identical cut segments 600, 602, 604, 606 and 608 by way of example, the portion of the cut stack indicated by cross hatching between out line 510 and the rear face of the stack 800 also preferably being discarded as waste material to provide a smooth planar sloping rear surface for the stack. These cut segments 600 to 608 are now preferably separable from each other and, as shown in FIGS. 3a, 3b, and 3d, each preferably comprise a pair of side faces which are rhomboidal in configuration as illustrated in FIG. 3b whereas the top, bottom, front and rear faces thereof are rectnagular in configuration. as illustrated in FIGS. 3a and 3d, a typical one of these cut portions 600 being illustrated in FIG. 3c. The cut portion 600, by way ofexample, is then preferably cut into a plurality of identical segments 620, 622, 624 and 626, four such segments being shown by way of example in FIG. 3!. along a line normal to the bottom face 407 to provide a plurality of batten-like members, such as members 32, 34, 36 and 38 previously described with reference to FIG. 7. For purposes of explanation, it shall be assumed that segments 620, 622, 624 and 626 correspond, respectively, to previously described batten-like members 32, 34, 36 and 38, respectively. Each of these batten-like members is preferably identical in configuration. As illustrated in FIG. 4, and as previously described, alternate batten-like members are preferably rotated 180 about the longitudinal axis 50 so that the end faces of the adjacent battenlike members which are preferably fastened or bonded together in the same fashion previously described with reference to the bonding of the boards comprising the stack 800, with the end faces of member 32, which corresponds to segment 620 and 34, which corresponds to segment 622 providing cross graining due to the acute angle 4), being formed between the end faces of batten-like member 32 and the longitudinal axis 50, and the obtuse angle B, which is supplementary thereto being formed between the longitudinal axis 50 of member 34 and the end faces thereof, the same being true with respect to members 36 and 38 as previously described. This fastened configuration of batten-like members is allowed to dry for sufficient time, such as 24 hours, and the ends thereof are preferably cut, such as along cut lines 700 and 702 as illustrated in FIG. 5, from side face to side face of the hardcore panel 30 as to provide a rectangular hardcore panel as illustrated in FIG. 7. FIG. 6 illustrates the location of this cutting, by way of example, in side elevation, in which the ends are squared off for the hardcore panel 30. Referring now to FIGS. 8, 9 and 10, veins, such as veins 54, 56, 58 and 60 of predetermined thickness may be provided in the hardcore panel in the same fashion as previously described above merely by inserting boards of lesser thickness, such as boards 601, 580, S60 and 540 between adjacent boards and 460, 460 and 440, 440 and 420, and 420 and 400, respectively, these boards preferably being a predetermined lesser thickness than the thickness of the boards 480, 460, 440, 420 and 400 while otherwise being preferably identical in dimension. Thereafter, this stack, which has preferably been fastened to gether by bonding in the manner previously described with respect to the stack of FIG. 1, is then treated in the same manner by cutting the stack from side to side along cut lines having a predetermined acute angle which is preferably identical with the acute angle :12, previously described with reference to the embodiment of FIG. I to provide batten-like members of the type illustrated in FIGS. 9 and 10. Accordingly, the method with respect to providing veins in the hardcore panel 38 is otherwise mechanical and atmospheric influences, such as by the use of varnishes, finishes or stains. Preferably, the spacing between the curs of the diagonal cut lines or planes is 7/8 of an inch, such spacing depending on the desired thickness of the final hardcore panel 30. Furthermore, as is readily apparent from the figures, the length of the final hardcore panel 30 which preferably comprises one batten-like member in length is determined by the height or number of boards in the stack 800.

it is to be understood that the above described em bodiments of the invention are merely illustrative of the principles thereof and that numerous modifications and embodiments of the invention may be derived within the spirit and scope thereof.

What is claimed is:

l. A method of making a hardcore panel comprising the steps of providing a stack comprising a plurality of parallel substantially uniform width planar boards of grained lumber fastened together and arranged in said stack in step-wise fashion, said stack having opposed top and bottom parallel faces, opposed front and rear faces and a pair of opposed parallel side faces, with the top and bottom faces and side faces being substantially planar and the front and rear faces being stepped from said bottom to said top face; initially completely cutting said stepped stack along a first cut line through said side faces from side face to side face at a predetermined acute angle between said first cut line and said bottom face to provide a substantially planar front face normal to said first cut line, said front face being sloped between said parallel planar top and bottom faces at said acute angle with respect to the plane of said bottom face; completely cutting said initially cut stepped stack at a predetermined distance from said first out line along said side face along a second cut line through said side faces from side face to side face at said predetermined acute angle between said second cut line and said bottom face to provide a first cut portion from said stepped stack having a substantially planar rear face for said first cut portion normal to said second cut line, said first cut portion front and rear faces being parallel; completely cutting said first cut portion through said first cut portion front face from said first cut portion front face to said first cut portion rear face along a third cut line normal to said bottom face to provide a first plurality of substantially identical cut segments each having said first cut portion sloping front and rear faces and whose top, front, bottom and rear faces are rectangular and whose side faces are rhomboidal, each of said first plurality of cut segments comprising said stack between said top and bottom faces with the top and bottom faces of each board in said stack being parallel to said cut segment top and bottom faces; and fastening said cut segments together with said front faces in a common plane with alternate adjacent fastened segments being rotated l80 about a longitudinal axis through the center of said segment parallel to said front face slope to provide a top and bottom surface for said fastened segments comprising alternating inverted sloping surfaces of said segment top and bottom faces whose slope is at an angle supplementary to said acute angle to provide said panel.

2. A method in accordance with claim 1 further comprising the steps of cutting said alternating inverted sloping surfaces of said fastened segments along a fourth cut line normal to said segment from face and a fifth cut line normal to said segment rear face to provide substantially planar top and bottom faces for said panel comprising said fastened segments which are parallel to each other and normal to said front and rear and side faces wherein the side faces of the component boards are at an angle to said bottom face supplementary to said acute angle.

3. A method in accordance with claim 1 wherein said acute angle is substantially between 12 and 30.

4. A method in accordance with claim 1 wherein said acute angle is substantially 18.

5. A method in accordance with claim 1 wherein said stack providing step comprises the step of fastening said stack together by gluing adjacent boards to each other with a waterproof resin.

6. A method in accordance with claim 1 wherein said segment fastening step comprises the step of fastening adjacent side surfaces of said cut segments to each other by gluing with a waterproof resin.

7. A method in accordance with claim 1 wherein said stack providing step comprises the further step of providing at least two boards in said stack of contrasting color to provide a decorative panel.

8. A method in accordance with claim 7 wherein said stack providing further step comprises the still further step of providing at least two boards of substantially the same thickness and a third board of lesser thickness sandwiched between said two boards and contrasting in color therewith to provide said decorative panel.

9. A method in accordance with claim 1 comprising the further step of routing said panel comprising said fastened segments to provide at least one groove of predetermined depth in said front face extending in a direction normal to and between said planar top and bottom faces to provide a decorative panel.

10. A method in accordance with claim 9 wherein said stack providing step comprises the further step of providing at least two boards in said stack of contrasting color to provide a decorative panel.

11. A method in accordance with claim 10 wherein said stack providing further step comprises the still further step of providing at least two boards of substantially the same thickness and a third board of lesser thickness sandwiched between said two boards and contrasting in color therewith to provide said decorative panel.

12. A method in accordance with claim 9 wherein said routing step comprises the step of routing said panel to provide at least one groove of predetermined depth in said rear face extending in the same direction as said front face groove.

13. A method in accordance with claim 1 wherein said stack providing step comprises the further step of stacking said plurality of boards with the grains thereof all running in the same direction 14. A method in accordance with claim 13 wherein said stack providing further step comprises stacking said plurality of boards with the grains thereof all running in the direction between said front and rear faces of said boards in said stack.

15. A method in accordance with claim 1 comprising the further step of fastening a veneer layer of a predetermined thickness to at least said front face of said panel to cover said front face.

16. A method in accordance with claim 15 wherein said veneer layer fastening step comprises fastening another veneer layer of a predetermined thickness to said rear face of said panel to cover said rear face, said panel being sandwiched between said veneer layers.

17. A hardcore panel comprising a plurality of adja cent batten-like members fastened together in a substantially planar configuration, each of said batten-like members having a top face, an opposed bottom face, a pair of opposed side faces, each of said faces being substantially normal to the adjacent face of said batten-like member, each of said batten-like members comprising a fastened plurality of stacked adjacent angular board segments of grained lumber, each of said segments having a top face, an opposed bottom face, a pair of opposed end faces and a pair of opposed side faces, said board segments being stacked along the longitudinal axis of said batten like member from one of said batten-like member end faces to said opposed end face. said adjacent angular board segment end faces being fastened together and being substantially parallel to each other. said adjacent angular board segments top. bottom and side faces comprising said batten-like member top, bottom and side faces respectively, each of said segment adjacent end faces for every other one of said fastened batten-like members in said plurality forming a predetermined acute angle with said longitudinal axis, each of said adjacent end faces comprising said batten-like members adjacent to said every other one in said plurality forming a predetermined obtuse angle with said longitudinal axis which is supplementary to said predetermined acute angle.

18. A hardcore panel in accordance with claim 17 wherein the grain of each of said segments comprising a given battenlike member all run in the same direction between said top surface and said bottom surface with the direction of the grain of each of said obtuse angular related segments substantially being supplementary to the direction of the grain of each of said acute angular related segments.

l9. A hardcore panel in accordance with claim 18 wherein said grain runs in a direction substantially coplanar with said segment end faces.

20. A hardcore panel in accordance with claim 17 wherein said acute angle is substantially between 12 and 30.

21. A hardcore panel in accordance with claim 17 wherein said acute angle is substantially 18.

22. A hardcore panel in accordance with claim 17 wherein at least two segments comprising at least one of said battenlike members are of contrasting color for providng a decorative panel.

23. A hardcore panel in accordance with claim 22 wherein at least one of said batten-like members comprises at least two segments of substantially the same thickness and a third segment of lesser thickness sandwiched between said two segments and contrasting in color therewith to provide said decorative panel.

24. A hardcore panel in accordance with claim 17 wherein said top face comprises at least one concave groove of predetermined depth extending in a direction between said end faces to provide a decorative panel.

25. A hardcore panel in accordance with calim 24 wherein at least two segments comprising at least one of said batten-like members are of contrasting color for providing said decorative panel.

26. A hardcore panel in accordance with claim 25 wherein at least one of said batten-like members comprises at least two segments of substantially the same thickness and a third segment of lesser thickness sandwiched between said two segments and contrasting in color therewith to provide said decorative panel.

27. A hardcore panel in accordance with claim 24 wherein said bottom face comprises at least one concave groove of predetermined depth extending in a direction between said end faces.

28. A hardcore panel in accordance with claim 17 further comprising a veneer layer having a predetermined thickness fastened to at least said top face of said panel to cover said top face.

29. A hardcore panel in accordance with claim 28 further comprising a second veneer layer having a predetermined thickness fastened to said bottom face of said panel to cover said bottom face, said panel being sandwiched between said veneer layers.

z gz g UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 95,144 4 Dated July 15, 1975 Inventor( JOHN KIEFER It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Title page, right side, line 17: "supplement-art" should read supplementary Column 1, line 16: "related" should read relates line 24: "pieces in this" should read pieces cut in this Column 2, line 19: "cutportions" should read cut portions Column 3, line 13: "intiially" should read initially line 19: "pluralith" should read plurality line 47: "lumberm" should read lumber Column 4, line 17: "toghether" should read together line 31: "exmaple" should read example line 57: "togehter" should read together line 65: "howeverl" should read however Column 6, line 55: "themoplastic" should read thermoplastic Column 7, lines 22-23: "and and" should read and line 42: "preferablu" should read preferably lines 62-63: "rectnagular" should read rectangular Column 8, line 12: "battenlike" should read batten-like-- line 45: "to gether" should read together @253? UNITED STATES PATENT OFFICE 2 CERTIFICATE OF CORRECTION Patent No. 3, 895, 144 Dated July 15, 1975 Inventor KIEFER It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column ll, line 17: "battenlike" should read battenlike Column 12, line 11: "calim" should read claim Sigurd and Scaled du's second Day of W197) [SEAL] Arrest:

RUTH C. MASON C. IAISIIALL DAN" Arresting Officer (ummissimm ufl'an'nls and Trademarks 

1. A METHOD OF MAKING A HARDCORE PANEL COMPRISING THE STEPS OF PROVIDING A STACK COMPRISING A PLURALITY OF PARALLEL SUBSTANTIALLY UNIFORM WIDTH PLANAR BOARDS OF GRAINED LUMBER FASTENED TOGETHER AND ARRANGED IN SAID STACK IN STEP-WISE FASHION, SAID STACK HAVING OPPOSED TOP AND BOTTOM PARLLEL FACES, OPPOSED FRONT AND REAR FACE AND A PAIR OF OPPOSED PARALLEL SIDE FACES, WITH THE TOP AND BOTTOM FACES AND SIDE FACES BEING SUBSTANTIALLY PLANAR AND THE FRONT AND REAR FACES BEING STEPPED FROM SAID BOTTOM TO SAID TOP FACE, INITIALLY COMPLETELY CUTTING SAID STEPPED STACK ALONG A FIRST CUT LINE THROUGH SAID SIDE FACES FROM SIDE FACE TO SIDE FACE AT A PREDETERMINED ACUTE ANGLE BETWEEN SAID FIRST CUT LINE AND SAID BOTTOM FACE TO PROVIDE A SUBSTANTIALLY PLANAR FRONT FACE NORMAL TO SAID FIRST CUT LINE, SAID FRONT FACE BEING SLOPED BETWEEN SAID PARALLEL PLANAR TOP AND BOTTOM FACES AT SAID ACUTE ANGLE WITH RESPECT TO THE PLANE OF SAID BOTTOM FACE, COMPLETELY CUTTING SAID INITIALLY CUT STEPPED STACK AT A PREDETERMINED DISTANCE FROM SAID FIRST CUT LINE ALONG SAID SIDE FACE ALONG A SECOND CUT LINE THROUGH SAID SIDE FACES FROM SIDE FACE TO SIDE FACE AT SAID PREDETERMINED ACUTE ANGLE BETWEEN SAID SECOND CUT LINE AND SAID BOTTOM FACE TO PROVIDE A FIRST CUT PORTION FROM SAID STEPPED STACK HAVING A SUBSTANTIALLY PLANAR REAR FACE FOR SAID FIRST CUT PORTION NORMAL TO SAID SECOND CUT LINE, SAID FIRST CUT PORTION FRONT AND REAR FACES BEING PARALLEL, COMPLETELY CUTTING SAID FIRST CUT PORTION THROUGH SAID FIRST CUT PORTION FRONT FACE FROM SAID FIRST CUT PORTION FRONT FACE TO SAID FIRST CUT PORTION REAR FACE ALONG ATHIRD CUT LINE NORMAL TO SAID BOTTOM FACE TO PROVIDE A FIRST PLURALITY OF SUBSTANTIALLY IDENTICAL CUT SEGMENTS EACH HAVING SAID FIRST CUT PORTION SLOPING FRONT AND REAR FACES AND WHOSE TOP, FRONT, BOTTOM AND REAR FACES ARE RECTANGULAR AND WHOSE SIDE FACES ARE RHOMBOIDAL, EACH OF SAID FIRST PLURALITY OF CUT SEGMENTS COMPRISING SAID STACK BETWEEN SAID TOP AND BOTTOM FACES WITH THE TOP AND BOTTOM FACES OF EACH BOARD IN SAID STACK BEING PARALLEL TO SAID CUT SEGMENT TOP AND BOTTOM FACES, AND FASTENING SAID CUT SEGMENTS TOGETHER WITH SAID FRONT FACES IN A COMMON PLANE WITH ALTERNATE ADJACENT FASTENED SEGMENTS BEING ROTATED 180* ABOUT A LONGITUDINAL AXIS THROUGH THE CENTER OF SAID SEGMENT PARALLEL TO SAID FRONT FACE SLOPE TO PROVIDE A TOP AND BOTTOM SURFACE FOR SAID FASTENED SEGMENTS COMPRISING ALTERNATING INVERTED SLOPING SURFACES OF SAID SEGMENT TOP AND BOTTOM FACES WHOSE SLOPE IS AT AN ANGLE SUPPLEMENTARY TO SAID ACUTE ANGLE TO PROVIDE SAID PANEL.
 2. A method in accordance with claim 1 further comprising the steps of cutting said alternating inverted sloping surfaces of said fastened segments along a fourth cut line normal to said segment front face and a fifth cut line normal to said segment rear face to provide substantially planar top and bottom faces for said panel comprising said fastened segments which are parallel to each other and normal to said front and rear and side faces wherein the side faces of the component boards are at an angle to said bottom face supplementary to said acute angle.
 3. A method in accordance with claim 1 wherein said acute angle is substantially between 12* and 30*.
 4. A method in accordance with claim 1 wherein said acute angle is substantially 18*.
 5. A method in accordance with claim 1 wherein said stack providing step comprises the step of fastening said stack together by gluing adjacent boards to each other with a waterproof resin.
 6. A method in accordance with claim 1 wherein said segment fastening step comprises the step of fastening adjacent side surfaces of said cut segments to each other by gluing with a waterproof resin.
 7. A method in accordance with claim 1 wherein said stack providing step comprises the further step of providing at least two boards in said stack of contrasting color to provide a decorative panel.
 8. A method in accordance with claim 7 wherein said stack providing further step comprises the still further step of providing at least two boards of substantially the same thickness and a third board of lesser thickness sandwiched between said two boards and contrasting in color therewith to provide said decorative panel.
 9. A method in accordance with claim 1 comprising the further step of routing said panel comprising said fastened segments to provide at least one groove of predetermined depth in said front face extending in a direction normal to and between said planar top and bottom faces to provide a decorative panel.
 10. A method in accordance with claim 9 wherein said stack providing step comprises the further step of providing at least two boards in said stack of contrasting color to provide a decorative panel.
 11. A method in accordance with claim 10 wherein said stack providing further step comprises the still further step of providing at least two boards of substantially the same thickness and a third board of lesser thIckness sandwiched between said two boards and contrasting in color therewith to provide said decorative panel.
 12. A method in accordance with claim 9 wherein said routing step comprises the step of routing said panel to provide at least one groove of predetermined depth in said rear face extending in the same direction as said front face groove.
 13. A method in accordance with claim 1 wherein said stack providing step comprises the further step of stacking said plurality of boards with the grains thereof all running in the same direction.
 14. A method in accordance with claim 13 wherein said stack providing further step comprises stacking said plurality of boards with the grains thereof all running in the direction between said front and rear faces of said boards in said stack.
 15. A method in accordance with claim 1 comprising the further step of fastening a veneer layer of a predetermined thickness to at least said front face of said panel to cover said front face.
 16. A method in accordance with claim 15 wherein said veneer layer fastening step comprises fastening another veneer layer of a predetermined thickness to said rear face of said panel to cover said rear face, said panel being sandwiched between said veneer layers.
 17. A hardcore panel comprising a plurality of adjacent batten-like members fastened together in a substantially planar configuration, each of said batten-like members having a top face, an opposed bottom face, a pair of opposed side faces, each of said faces being substantially normal to the adjacent face of said batten-like member, each of said batten-like members comprising a fastened plurality of stacked adjacent angular board segments of grained lumber, each of said segments having a top face, an opposed bottom face, a pair of opposed end faces and a pair of opposed side faces, said board segments being stacked along the longitudinal axis of said batten-like member from one of said batten-like member end faces to said opposed end face, said adjacent angular board segment end faces being fastened together and being substantially parallel to each other, said adjacent angular board segments top, bottom and side faces comprising said batten-like member top, bottom and side faces respectively, each of said segment adjacent end faces for every other one of said fastened batten-like members in said plurality forming a predetermined acute angle with said longitudinal axis, each of said adjacent end faces comprising said batten-like members adjacent to said every other one in said plurality forming a predetermined obtuse angle with said longitudinal axis which is supplementary to said predetermined acute angle.
 18. A hardcore panel in accordance with claim 17 wherein the grain of each of said segments comprising a given battenlike member all run in the same direction between said top surface and said bottom surface with the direction of the grain of each of said obtuse angular related segments substantially being supplementary to the direction of the grain of each of said acute angular related segments.
 19. A hardcore panel in accordance with claim 18 wherein said grain runs in a direction substantially coplanar with said segment end faces.
 20. A hardcore panel in accordance with claim 17 wherein said acute angle is substantially between 12* and 30*.
 21. A hardcore panel in accordance with claim 17 wherein said acute angle is substantially 18*.
 22. A hardcore panel in accordance with claim 17 wherein at least two segments comprising at least one of said battenlike members are of contrasting color for providng a decorative panel.
 23. A hardcore panel in accordance with claim 22 wherein at least one of said batten-like members comprises at least two segments of substantially the same thickness and a third segment of lesser thickness sandwiched between said two segments and contrasting in color therewith to provide said decorative panel.
 24. A hardcore panel in accordance with claim 17 wherein said top facE comprises at least one concave groove of predetermined depth extending in a direction between said end faces to provide a decorative panel.
 25. A hardcore panel in accordance with calim 24 wherein at least two segments comprising at least one of said batten-like members are of contrasting color for providing said decorative panel.
 26. A hardcore panel in accordance with claim 25 wherein at least one of said batten-like members comprises at least two segments of substantially the same thickness and a third segment of lesser thickness sandwiched between said two segments and contrasting in color therewith to provide said decorative panel.
 27. A hardcore panel in accordance with claim 24 wherein said bottom face comprises at least one concave groove of predetermined depth extending in a direction between said end faces.
 28. A hardcore panel in accordance with claim 17 further comprising a veneer layer having a predetermined thickness fastened to at least said top face of said panel to cover said top face.
 29. A hardcore panel in accordance with claim 28 further comprising a second veneer layer having a predetermined thickness fastened to said bottom face of said panel to cover said bottom face, said panel being sandwiched between said veneer layers. 